TurnKey Corrections constructed a new 115,000-square-foot in facility in River Falls, Wis.

If you want it done right, do it yourself. Company owners Todd Westby and Tim Westby take a hands-on approach to running TurnKey Corrections, the River Falls, Wisconsin-based company that provides commissary and jail management services to county corrections facilities nationwide. The Westby brothers also take pride in the fact that TurnKey manufactures the kiosks it provides to its clients and develops and owns the proprietary software used to run them.

So, it’s perhaps not surprising that, when building the company’s new headquarters, Todd Westby, the company’s CEO, founder and general manager, served as the general contractor. Or that he had definite ideas regarding the roofing system that would be installed. Or that he was more than willing to get his hands dirty during the installation process.

Founded in 1998, TurnKey Corrections helps corrections facilities streamline and lower the cost of delivering a variety services to inmates, including commissary, email and email-to-text communication, video visitation, law library access, and paperless intra-facility communication and documentation. Following several years of robust growth, the company had outgrown its three existing buildings. So, it constructed a new 115,000-square-foot facility to bring all operations, including 50,000 square feet of office space and a 65,000 square-foot warehouse where commissary items are stored prior to shipment to corrections facilities, under a single roof and accommodate future success.

“We wanted to be involved in the project from beginning to end so we knew what we were getting and how it was built,” Todd Westby says of the decision to keep construction management in-house. “We wanted to know about anything and everything that was being built for the company in this building.”

In planning the project, Westby initially set two key criteria for the roofing system: that the building would be made watertight as quickly as possible so concrete slab pours and other interior work could be completed, and that the roof would be covered by a warranty of at least 20 years. The design-build firm’s initial plans called for a ballasted EPDM roofing system, but Rex Greenwald, president of roofing contractor TEREX Roofing & Sheet Metal LLC of Minneapolis, suggested a white TPO system, noting that it would meet the quick installation and warranty goals while also enhancing the building’s energy efficiency. Westby was intrigued and, after some research, agreed to the recommendation. In addition to helping reduce cooling costs during summer months, the reflective surface would allow a blanket of snow to remain on the roof during winter months to provide additional insulation.

The TPO roofing system was constructed over a 22-gauge metal fabricated roof deck.

The Roof System

The TPO roofing system included a 22-gauge metal fabricated roof deck; two 2.5-inch-thick layers of Poly ISO insulation from Mule-Hide Products Co., with tapered insulation saddles and crickets to aid drainage; and 811 squares of 60-mil white TPO membrane from Mule-Hide Products Co. The insulation and membrane were mechanically attached using the RhinoBond System from OMG Roofing Products. Cast iron roof drains, designed and installed by a plumber, were used rather than scuppers and downspouts—a practice that the TEREX team strongly recommends to prevent freezing during the cold Upper Midwest winters. Walkways lead to the mechanical units, protecting the membrane from damage when maintenance personnel need to access the equipment.

The TEREX team finds the RhinoBond System to be the most efficient and economical attachment method for TPO systems. Specially coated metal plates are used to fasten the insulation to the roof deck and then an electromagnetic welder is used to attach the membrane to the plates. The membrane is not penetrated, eliminating a potential entry point for moisture. And while other mechanical attachment methods require the crew to seam as they go, the RhinoBond System allows them to lay the entire membrane (a task which must be completed in good weather conditions) at once and go back later to induction weld the seams and plates, which can be done when Mother Nature is slightly less cooperative.

Greenwald estimates that the switch from the originally specified ballasted EPDM system to the TPO roofing system and RhinoBond System shaved at least 10 percent off the installation time and reduced the roof weight by 10 pounds per square foot.

Having Westby on-site as the general contractor also sped up the project considerably, Greenwald notes. “He was a huge asset to all of the subcontractors,” he explains. “We could get construction questions answered quickly and could talk through issues and procedures on a timely basis.”

And the most memorable moment in the project for Greenwald was seeing Westby working side-by-side with his crew. “One day we had a delivery truck show up, and Todd jumped on the forklift and helped us unload the truck.”

As sought from the project’s outset, the roofing system is backed by a 20-year, no-dollar-limit labor and material warranty.

With one winter of use in the rearview mirror, the roofing system has exceeded Westby’s expectations. Warehouse space was doubled, but heating costs have been cut in half. The 10-unit heating system also is able to keep the warehouse a uniform temperature, without the cold spots that were common in the old building.

“It really is a beautiful, very efficient and organized-looking roof,” Greenwald says.

The sneak peeks will be held at OMG’s Exhibitor Product Clinics scheduled for 11:30 a.m., 1 p.m., 2:30 p.m. and 4 p.m. on the first two days of the show, March 1st and 2nd. During these demonstrations, OMG Roofing Products will showcase developments to the RhinoBond Induction Welding System, new drain products as well as updated edge metal products. The demonstrations, which will highlight roof-top productivity and performance benefits, are open to all IRE participants. Stadium seating is available on a first-come, first-served basis.

In addition to the sneak peeks, OMG Roofing Products will also hold a silent auction for a custom painted OMG PaceCart 3, a 15 Gallon Drum Conversion Kit, and two sets (a total of 60 gallons) of OlyBond500 in 15 Gallon Drums. The OlyBond package has an estimated value of over $11,000, and proceeds from the silent auction will benefit OMG’s named scholarship, which is part of the Melvin Kruger Endowed Scholarship Program offered through the National Roofing Contractors Association.

OMG Roofing Products demonstrated its new RhinoBond Foil Tool, an induction welding system for securing single-ply commercial roofing membranes, at the BAU show in Munich.

OMG’s RhinoBond Foil Tool is specifically designed for use over foil face PIR insulation. The welding tool includes plate sensor technology to help users locate RhinoBond Plates installed under the roofing membrane, and assists with tool alignment for optimum bonding. A tone and a visual indicator light lets operators know when the weld cycle is complete.

The RhinoBond System is induction based technology used for installing commercial roofing systems. To date, more than 170 million m2 of commercial roofing membranes have been installed around the globe with RhinoBond, including more than 125 projects in Europe accounting for more than 3,200,000 m2.

The company was also looking for new distribution partners in targeted geographies throughout Europe during the show.

“As more roofing contractors have seen the labor savings and roof performance benefits that the RhinoBond System can offer, we have had tremendous growth,” says Lennard Spirig, Europe market manager. ”With updated technology and expanded distribution, we expect acceptance of the RhinoBond System across the region.”

RhinoBond is a method for installing thermoplastic and soon will be available for certain clean EPDM membrane. The system consists of a stand-up induction welding tool and magnetic cooling clamps. Contractors install roofing insulation using fasteners and specially coated plates designed specifically for the type of membrane being installed – PVC, TPO or Clean EPDM. Each plate is then bonded to the roof membrane installed over the top with the RhinoBond plate welding tool. The result is a roofing system that can provide enhanced wind performance with fewer fasteners, fewer membrane seams and zero penetrations of the new membrane.

OMG Roofing’s RhinoBond System has left marks across Europe with more than 125 completed projects and more in the pipeline. Collectively, these projects represent more than 300,000 square meters (3.2 million square feet) of single-ply roofing.

“In last two years, the RhinoBond System has started to take off across Europe, as more roofing contractors have seen the roof performance benefits that the system can offer,” states Web Shaffer, vice president of marketing for OMG Roofing Products. “We have completed projects across Europe and we are expanding to new countries in the region, most recently, into South East Europe.”

RhinoBond is a method for installing thermoplastic and now also clean EPDM membrane. The system consists of a stand-up induction welding tool and magnetic cooling clamps. Contractors install roofing insulation using fasteners and specially coated plates designed specifically for the type of membrane being installed – PVC, TPO or Clean EPDM. Each plate is then bonded to the roof membrane installed over the top with the RhinoBond plate welding tool. The result is a roofing system that can provide wind performance with fewer fasteners, fewer membrane seams and zero penetrations of the new membrane.

OMG Roofing Products has launched a webpage designed to provide RhinoBond users with fast and easy access to critical system resources they may need while on the job site. The page includes access to the RhinoBond operating manual and the RhinoBond Best Practice tip sheet in English and Spanish. In addition, six videos are accessible from the site, including three videos about the system, wind performance and use over standing-seam metal roofs, and three how-to videos covering start-up requirements, tool calibration and magnet rotation.

OMG Roofing Products of Agawam, Mass. has launched a new webpage designed to provide RhinoBond users with access to system resources that they may need while on the jobsite.

The web page, www.RhinoBondResources.com, includes access to the RhinoBond operating manual and the RhinoBond Best Practice tip sheet, both are provided in English and Spanish. In addition, six videos are accessible from the site, including three videos about the system, wind performance and use over standing seam metal roofs, and three “how to” videos covering start-up requirements, tool calibration and magnet rotation.

RhinoBond, designed for use with thermoplastic PVC and TPO roofing systems, uses induction welding technology to bond the membrane directly to coated plates that are used to secure the insulation to the deck, all without penetrating the roofing membrane. The result is a roofing system with wind performance that requires up to 50 percent fewer fasteners and plates and up to 30 percent fewer membrane seams to weld on the roof.

“Roofers have a challenge of keeping crew-members up-to-date when it comes to training and best practices,” said David Allor, RhinoBond product manager for OMG Roofing Products. “Therefore we’ve made the information available from anywhere by going to the website, or by scanning a QR Code that is displayed on a yellow sticker on the inside of the RhinoBond tool case.”

Roofing contractors who want to add yellow reminder stickers to the inside of their existing RhinoBond tool cases, should contact their local OMG Field Service Representative or order stickers directly at the website.

To support a goal of accelerating international sales growth in Asia and Europe, OMG Roofing Products has established warehouses in Rotterdam in the Netherlands as well as in Shanghai, China.

The two warehouses are centrally located within their regions to enable OMG to supply products to roofing contractors and OEM partners in each of these markets. Both warehouses will stock a range of products sold locally, including OMG Fasteners and Plates, RhinoBond Tools and Plates, OMG Telescopic Tubes, OlyBond500 insulation adhesives, OlyFlow Drains, and EverSeal Roof Repair Tape.

“OMG Roofing Products has continued to grow and expand beyond U.S. borders,” said Web Shaffer, vice president of marketing. “By adding these warehouses we are building a foundation on which to accelerate our international growth by improving our service and expanding our distribution into new countries throughout Europe and Asia.”

Kingbill Zhao, Asia market manager, is based in China and will support the greater Asian market.

With the goal of accelerating growth in international markets, OMG Roofing Products creates market manager positions for both Asia and Europe. Two executives receive promotions into these roles. Kingbill Zhao, Asia market manager, is based in China and will support the greater Asian market. Lennard Spirig, Europe market manager, is based in Switzerland servicing the European market. Both are responsible for all OMG sales and marketing activities in their regions including developing products and services tailored to local market needs.

Kingbill Zhao joined OMG in 2009 as a roofing specialist and was promoted to China sales manager in 2011, where he was responsible for launching the OMG Roofing Products line in China. Since then, Kingbill has built a sales and customer service organization in China to support the company’s rapidly growing business. Prior to joining OMG, Kingbill was the international department manager for the China Waterproofing Association (CWA) where he worked with other international counterparts like National Roofing Contractors Association (NRCA), Germany Roofing Contractors Association (GRCA) to market China Roofing & Waterproofing Show internationally. In addition he organized Chinese company visits in US and Europe, and worked with organizations like FM Global and FLL to introduce approvals and standards to China.

Lennard Spirig, Europe market manager, is based in Switzerland servicing the European market.

“Lennard Spirig joined OMG in 2014 as Europe product marketing manager, responsible for marketing OMG products throughout Europe. Since then, Lennard has been a resource for helping to expand OMG’s footprint in Europe by assisting system manufacturer partners and by developing distribution in various European countries. Prior to joining OMG Roofing Products, Lennard spent 10 years as product manager for mechanical attachment with SFS Intec. Earlier he had been an international key account manager based in Mexico.

“OMG’s products are designed to enhance rooftop productivity and improve roof system performance,” said Web Shaffer, vice president of marketing. “Lennard and Kingbill will be focused on developing value-added products and services that meet local market needs in order to accelerate our growth in Europe and Asia respectively. I look forward to continuing to work with these two outstanding individuals.”

Headquartered in Agawam, Massachusetts, U.S.A., OMG Roofing Products is a supplier of commercial roofing products including specialty fasteners, insulation adhesives, roof drains, pipe supports, emergency repair tape as well as productivity tools such as the RhinoBond induction welding system. The company’s focus is delivering products and services that improve contractor productivity and enhance roof system performance.

The project also included 35 squares of copper standing-seam roofing, 25 squares of soldered copper flat-seam roofing and 115 squares of copper wall cladding. About 58,000 pounds of copper were installed on the brewery.

Everything on the building is oversized and that meant everything had to be built to support the heavy structural loads and live loads from wind and mountain snow. The large roof faces called for 10-inch custom copper gutters. When you have gutters that large in the mountains of North Carolina you have to consider the extraordinary weight of the annual snow.

In addition to snow guards being installed on the slate roof, custom 1/4-inch-thick copper gutter brackets fastened the gutter to the fascia. It is typical on steel-framed construction, particularly on this scale, that the framing is out of square and there is widely varying fascia and rake dimensions.

Approximately 423 squares of 1/2-inch-thick, 18-inch-tall by random width Unfading Green Slates were installed by hand on the project.

However, these items should not appear out of square or have varying dimensions. Great care had to be taken to measure and custom bend onsite all the detail flashings so everything appeared perfect. This took many skilled craftsmen, a great deal of time and the absolute drive to provide the highest quality work.

ROOF REPORT

The new-construction project began in November 2013 and was completed in September 2015.
The team completed the slate installation so well that The Century Slate Co. was awarded the 2015 Excellence in Craftsmanship Award by Evergreen Slate for the project.

OMG Roofing Products has unveiled a video showcasing how easy it is to install thermoplastic single-ply membranes on standing-seam metal recover projects using the RhinoBond induction welding system.

OMG Roofing Products has unveiled a video showcasing how easy it is to install thermoplastic single-ply membranes on standing-seam metal recover projects using the RhinoBond induction welding system. The video offers a step-by-step demonstration of the application and highlights the ways the RhinoBond System eliminates the traditional hassles of this type of application, including the following:

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January/February 2018

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About Roofing

Roofing is a national publication that unravels, investigates and analyzes how to properly design, install and maintain a roof system. Through the voices of professionals in the field, Roofing’s editorial provides a unique perspective.